U.S. patent number 10,797,541 [Application Number 16/240,015] was granted by the patent office on 2020-10-06 for magnetic plate laminate, manufacturing method therefor, and motor using this laminate.
This patent grant is currently assigned to PANASONIC CORPORATION. The grantee listed for this patent is PANASONIC CORPORATION. Invention is credited to Mituhiro Ikeda, Yukio Nishikawa, Naoki Nojiri.
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United States Patent |
10,797,541 |
Nishikawa , et al. |
October 6, 2020 |
Magnetic plate laminate, manufacturing method therefor, and motor
using this laminate
Abstract
Provided is a magnetic plate laminate comprising a laminate
formed by stacking a plurality of thin strips, and fastening
members provided in apertures in the laminate. Also provided is a
method for manufacturing a magnetic laminate wherein the thin
strips are amorphous thin strips and the magnetic body laminate is
subjected to heat treatment, thereby forming nano-crystalline
grains in the thin strips. Also provided is a motor equipped with a
stator formed by stacking a plurality of the magnetic plate
laminates, a securing plate for securing the stator, and a rotor
arranged in an opening in the middle of the stator.
Inventors: |
Nishikawa; Yukio (Osaka,
JP), Ikeda; Mituhiro (Hyogo, JP), Nojiri;
Naoki (Osaka, JP) |
Applicant: |
Name |
City |
State |
Country |
Type |
PANASONIC CORPORATION |
Osaka |
N/A |
JP |
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Assignee: |
PANASONIC CORPORATION (Osaka,
JP)
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Family
ID: |
1000005099181 |
Appl.
No.: |
16/240,015 |
Filed: |
January 4, 2019 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20190157921 A1 |
May 23, 2019 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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PCT/JP2017/023005 |
Jun 22, 2017 |
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Foreign Application Priority Data
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Jul 6, 2016 [JP] |
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2016-133842 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H02K
1/185 (20130101); H02K 1/146 (20130101); H02K
15/022 (20130101); H02K 15/02 (20130101); H02K
2201/09 (20130101) |
Current International
Class: |
H02K
1/18 (20060101); H02K 15/02 (20060101); H02K
1/14 (20060101) |
Field of
Search: |
;310/216.009 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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102361374 |
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Feb 2012 |
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CN |
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102868241 |
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Jan 2013 |
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CN |
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18 08 577 |
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Aug 1969 |
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DE |
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11 2014 000596 |
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Jan 2016 |
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DE |
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49-085502 |
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Aug 1974 |
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JP |
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S61-123672 |
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Aug 1986 |
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JP |
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S61-258655 |
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Nov 1986 |
|
JP |
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S61-205241 |
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Dec 1986 |
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JP |
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06-145917 |
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May 1994 |
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JP |
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H11-266555 |
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Sep 1999 |
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JP |
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2000-270505 |
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Sep 2000 |
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JP |
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2007-311652 |
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Nov 2007 |
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JP |
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2009-219309 |
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Sep 2009 |
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JP |
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2011-019400 |
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Jan 2011 |
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JP |
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2011-078167 |
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Apr 2011 |
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JP |
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99/27633 |
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Jun 1999 |
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WO |
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2014/024988 |
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Feb 2014 |
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WO |
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2015/159322 |
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Oct 2015 |
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WO |
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2016/035191 |
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Mar 2016 |
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WO |
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Other References
Translation of foreign document JP 49085502 A (Year: 1974). cited
by examiner .
Extended European Search Report dated Jun. 13, 2019 issued in
corresponding European Patent Application No. 17824024.8. cited by
applicant .
International Search Report and Written Opinion issued in
International Patent Application No. PCT/JP2017/023005, dated Sep.
19, 2017; with English translation. cited by applicant .
English translation of Search Report dated Feb. 3, 2020, issued in
the corresponding Chinese Patent Application 201780040568.8. cited
by applicant.
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Primary Examiner: Mok; Alex W
Attorney, Agent or Firm: McDermott Will & Emery LLP
Parent Case Text
CROSS-REFERENCE OF RELATED APPLICATIONS
This application is a Continuation of International Patent
Application No. PCT/JP2017/023005, filed on Jun. 22, 2017, which in
turn claims the benefit of Japanese Application No. 2016-133842,
filed on Jul. 6, 2016, the entire disclosures of which Applications
are incorporated by reference herein.
Claims
The invention claimed is:
1. A magnetic-plate laminate, comprising: a laminate in which a
plurality of thin strips are laminated; and a fastening member that
is provided in an opening of the laminate, wherein: the fastening
member includes a hollow cylinder, and a plurality of planar
portions which are located at each end of the cylinder, each planar
portion having a plate shape and extending from a corresponding end
of the cylinder in a vertical direction of the cylinder, each thin
strip has a thickness of 10 to 100 .mu.m, and each thin strip
includes an amorphous material.
2. The magnetic-plate laminate according to claim 1, wherein an
insulation layer is formed on an inner surface or an outer
peripheral surface of the hollow cylinder.
3. The magnetic-plate laminate according to claim 1, wherein a
material of the fastening member is non-magnetic.
4. The magnetic-plate laminate according to claim 1, wherein a
material of the fastening member is an austenitic iron-based
alloy.
5. The magnetic-plate laminate according to claim 1, wherein a
material of the fastening member is a nonferrous metal or an alloy
of the nonferrous metal.
6. A method for manufacturing the magnetic-plate laminate, wherein
the magnetic-plate laminate according to claim 1 in which the thin
strips are amorphous thin strips is thermally processed to cause
the stripes to have a nanocrystal grain.
7. A magnetic-plate laminate, comprising: a laminate in which a
plurality of thin strips are laminated; and a fastening member that
is provided in an opening of the laminate, wherein the fastening
member includes a solid or hollow columnar body, and planar
portions which are located at both ends of the solid or hollow
columnar body, an outer peripheral surface of the solid or hollow
columnar body includes a projection portion, wherein the projection
portion is located between two surfaces of the plurality of thin
strips which surfaces are facing each other in parallel, each thin
strip has a thickness of 10 to 100 .mu.m, and each thin strip
includes an amorphous material.
8. The magnetic-plate laminate according to claim 7, wherein an
insulation layer is formed on the outer peripheral surface of the
solid or hollow columnar body.
9. A motor, comprising: a stator which is a laminate of a plurality
of magnetic-plate laminates, each of the magnetic-plate laminates
including a laminate of a plurality of thin strips and a fastening
member that is provided in an opening of the laminate; a fixing
plate that fixes the stator; and a rotor that is disposed in an
opening at a center of the stator, wherein, in the stator, the
plurality of laminates face each other, and the fastening member is
provided in one of the openings of the two facing laminates and is
not provided in the opening of the other of the two facing
laminates.
10. The motor according to claim 9, wherein a plurality of openings
are provided with the laminate, the fastening member is provided in
at least one of the plurality of openings, and the fastening member
is not provided in the remainder of the openings.
11. The motor according to claim 9, wherein the opening in which
the fastening member is provided and the opening in which the
fastening member is not provided are alternately arranged in the
thickness direction of the stator.
Description
TECHNICAL FIELD
The present invention relates to a magnetic-plate laminate formed
by laminating soft magnetic thin strips, and also to a motor which
uses this laminate as a stator.
BACKGROUND ART
Pure iron and electromagnetic steel plates are used for magnetic
plates of iron cores (stators) for conventional motors.
Furthermore, for a motor which aims higher efficiency, thin strips
having an amorphous property or nanocrystal grains are used for an
iron core (see, for example, Patent Literature (hereinafter,
referred to as "PTL") 1). The stator iron core according to PTL 1
is formed by machining first the amorphous alloy thin strips made
by a liquid quenching method such as a single roll technique or a
twin roll technique in a predetermined shape by a method such as
winding, cutting, punching and etching.
By contrast with this, FIG. 16 illustrates a perspective view of an
amorphous lamination member 51 according to PTL 2. The lamination
member 51 is manufactured by overlapping, from upper and lower
sides, electromagnetic steel plates 53 on a plurality of sheets of
the amorphous alloy thin strips 52 to which an adhesive has been
applied, and heating and pressure-bonding the amorphous alloy thin
strips 52. Consequently, handling is easy.
CITATION LIST
Patent Literature
PTL 1
Japanese Patent Application Laid-Open No. H06-145917 PTL 2
Japanese Patent Application Laid-Open No. 2007-311652
SUMMARY OF INVENTION
Technical Problem
However, according to a configuration in PTL 1, when amorphous or
crystallized soft magnetic thin strips are laminated to make parts
such as iron cores, the thin strips are processed one by one.
Therefore, the number of times of processing for each process
performed until the thin belts reach a predetermined lamination
thickness increases many times, and productivity is low.
Furthermore, according to a configuration in PTL 2 in FIG. 16, the
adhesive enters between the layers of the amorphous thin strips,
and therefore there are problems that a space factor is poor and
motor efficiency becomes poor.
The present invention solves the conventional problems, and an
object of the present invention is to provide a magnetic-plate
laminate which has high productivity without impairing magnetic
characteristics, and a motor which uses this laminate.
Solution to Problem
To achieve the above object, there is used A magnetic-plate
laminate, including: a laminate in which a plurality of thin strips
are laminated; and a fastening member that is provided in an
opening of the laminate. Furthermore, there is used a method for
manufacturing the magnetic-plate laminate, in which the
magnetic-plate laminate in which the thin strips are amorphous thin
strips is thermally processed to cause the stripes to have a
nanocrystal grain. There is used a motor, including: a stator in
which a plurality of the magnetic-plate laminates are laminated; a
fixing plate that fixes the stator; and a rotor that is disposed in
an opening at a center of the stator.
A magnetic-plate laminate according to the present invention can
simultaneously handle a plurality of positioned thin strips and,
consequently, not only has high productivity but also does not
include a material which decreases a ratio of a magnetic member in
a unit volume such as an adhesive between layers, therefore has a
high space factor and can prevent a decrease in magnetic
characteristics.
As a result, the magnetic-plate laminate according to the present
invention has high productivity without impairing magnetic
characteristics.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A is a side view of a fastening member which fastens a
laminate according to Embodiment 1;
FIG. 1B is a broken cross-sectional view illustrating a
manufacturing process of a magnetic-plate laminate for which an
eyelet structure is used according to Embodiment 1;
FIG. 1C is a broken cross-sectional view illustrating the
manufacturing process of the magnetic-plate laminate for which the
eyelet structure is used according to Embodiment 1;
FIG. 1D is a broken cross-sectional view illustrating the
manufacturing process of the magnetic-plate laminate for which the
eyelet structure is used according to Embodiment 1;
FIG. 2 is a broken cross-sectional view illustrating a state where
the laminated laminate is fixed by eyelet members according to
Embodiment 2;
FIG. 3 is an external outlook view of the eyelet member of the
magnetic-plate laminate according to Embodiment 2;
FIG. 4A is a broken cross-sectional view illustrating the
manufacturing process of the magnetic-plate laminate according to
Embodiment 3;
FIG. 4B is a broken cross-sectional view illustrating the
manufacturing process of the magnetic-plate laminate according to
Embodiment 3;
FIG. 4C is a broken cross-sectional view illustrating the
manufacturing process of the 1 magnetic-plate laminate according to
Embodiment 3;
FIG. 5 is a broken cross-sectional view illustrating a state where
the laminated laminate is fixed by the caulking members according
to Embodiment 3;
FIG. 6A is a broken cross-sectional view illustrating a process of
forming the eyelet structures of the magnetic-plate laminate
according to Embodiment 4;
FIG. 6B is a broken cross-sectional view illustrating a process of
forming the eyelet structures of the magnetic-plate laminate
according to Embodiment 4;
FIG. 7A is a broken cross-sectional view illustrating the
manufacturing process of the magnetic-plate laminate for which a
caulking structure is used according to Embodiment 5;
FIG. 7B is a broken cross-sectional view illustrating the
magnetic-plate laminate for which the caulking structure is used
according to Embodiment 5;
FIG. 7C is a broken cross-sectional view illustrating the
manufacturing process of the magnetic-plate laminate for which the
caulking structure is used according to Embodiment 5;
FIG. 8 is an enlarged broken cross-sectional view near the caulking
member of the magnetic-plate laminate according to Embodiment
6;
FIG. 9 is an enlarged broken cross-sectional view near the caulking
member of the magnetic-plate laminate according to Embodiment
7;
FIG. 10A is a side view of a motor formed by the magnetic-plate
laminate according to Embodiment 8;
FIG. 10B is a top view of the motor formed by the magnetic-plate
laminate according to Embodiment 8;
FIG. 11A is a broken cross-sectional view between A and A' in FIG.
10B according to Embodiment 8;
FIG. 11B is a broken cross-sectional view between A and A' in FIG.
10B according to Embodiment 8;
FIG. 12 is an enlarged broken cross-sectional view near the eyelet
portions of the magnetic-plate laminate according to Embodiment
9;
FIG. 13A is a side view of the motor formed by the magnetic-plate
laminate according to Embodiment 10;
FIG. 13B is a top view of the motor formed by the magnetic-plate
laminate according to Embodiment 10;
FIG. 14 is a broken cross-sectional view between B and B' in FIG.
13B according to Embodiment 10;
FIG. 15 is a broken cross-sectional view between B and B' in FIG.
13B; and
FIG. 16 is a perspective view illustrating a conventional
magnetic-plate laminate disclosed in PTL 2.
DESCRIPTION OF EMBODIMENTS
A magnetic-plate laminate and a motor according to embodiments will
be described below with reference to the accompanying drawings. In
addition, the substantially same components in the drawings will be
assigned the same reference numerals.
Embodiment 1
FIG. 1A is a side view of fastening member 100a which fastens
magnetic-plate laminate 1. FIGS. 1B to 1D are schematic views
illustrating a manufacturing process of magnetic-plate laminate 1
according to Embodiment 1, and, more specifically, illustrate that
an eyelet structure is used as a metal fastening mechanism.
<Eyelet Structure 3a>
Fastening member 100a includes a plurality of planar portions 2a
which are partitioned by cuts at both ends of hollow cylinder 2. In
this regard, eyelet structure 3a is a structure that planar
portions 2a are located at the both ends of hollow cylinder 2 in a
vertical direction of the cylinder. Eyelet structure 3a is fitted
in opening 4 formed in magnetic-plate laminate 1 formed by
laminating thin strips which are magnetic bodies. Eyelet structure
3a includes planar portions 2a at the both ends of hollow cylinder
2 so as not to be detached easily from opening 4. As a result,
eyelet structure 3a can collectively fix magnetic-plate laminate 1
formed by laminating a plurality of thin strips. Furthermore,
eyelet structure 3a is also referred to as a grommet or an eyelet.
In addition, hollow cylinder 2 may be a columnar type or a
polygonal columnar shape.
FIGS. 1B to 1D illustrate laminate 1, hollow cylinder 2, planar
portions 2a formed at cuts on hollow cylinder 2, and opening 4
formed in magnetic-plate laminate 1. Opening 4 is a hole which
penetrates magnetic-plate laminate 1. The fastening member in FIG.
1A is inserted in this opening 4.
<Process>
First, in FIG. 1B, the fastening member in FIG. 1B including hollow
cylinder 2 and planar portions 2a is inserted in opening 4 of
magnetic-plate laminate 1 in an arrow direction.
Next, in FIG. 1C, laminated magnetic-plate laminate 1 is fixed by
pressing mechanisms 5, and eyelet fittings 6 are butted from upper
and lower sides in arrow directions to push open planar portions
2a.
Furthermore, in FIG. 1D, compressing fittings 7 perform compression
from the arrow directions (from the upper and lower sides) to make
planar portions 2a face left and right directions to form eyelet
structure 3a. The compression may be height regulation which can
keep the fixed height of the eyelet, or pressure regulation which
can make the eyelet firm.
FIG. 2 is a cross-sectional view illustrating a state where
laminated magnetic-plate laminate 1 is fixed by eyelet structures
3a.
<Magnetic-Plate Laminate>
Magnetic-plate laminate 1 is formed by laminating the thin strips.
In this case, the thin strip is an amorphous magnetic plate. The
plate thickness of the thin strip obtained in an amorphous state is
usually between 10 and 100 .mu.m. Furthermore, the thin strip may
be an amorphous thin strip crystalized by heat processing.
<Material of Fastening Member 100a>
A material of fastening member 100a is desirably a non-magnetic
material which is not influenced by a magnetic field from a
viewpoint that this material does not influence magnetic
characteristics of magnetic-plate laminate 1. As this non-magnetic
material, an iron-based material such as austenitic stainless
steel, or a non-ferrous metal such as a cooper, a copper-based
alloy such as brass, aluminum or an aluminum alloy, or an alloy of
these metal can be used.
Eyelet structure 3a of fastening member 100a made of brass fixes 30
sheets of amorphous thin strips (thin strips) to handle as one
magnetic-plate laminate 1. The thicknesses of upper and lower
planar portions 2a of eyelet structure 3a are 60 .mu.m in total,
and, when the thickness of the thin strip (thin strip) is 30 .mu.m,
a space factor indicating occupation of the thin strips in a
lamination thickness direction is approximately 94%. As the plate
thicknesses and the number of sheets of the thin strips are larger
and planar portions 2a are thinner, the space factor is higher. A
lamination thickness limit of the thin strips depends on eyelet
structure 3a, and, as the lamination thickness is thicker, planar
portions 2a and thicker eyelet structure 3a are necessary.
Eyelet structure 3a may be formed in magnetic-plate laminate 1 of
the crystalized thin strips or eyelet structure 3a may be formed in
magnetic-plate laminate 1 of the amorphous thin strips, then be
thermally processed and crystallized.
A crystallization temperature varies based on a composition and is
usually between 350.degree. C. and 500.degree. C., and when a
nanocrystal grain whose diameter is several 10 nm or less is
included in the thin strip, the thin strip has better soft magnetic
characteristics than an amorphous member.
In addition, when crystallized from the amorphous state, the thin
strip becomes fragile, and therefore when eyelet structure 3a is
formed after the crystallization, it is necessary to pay attention
not to break the thin strips.
On the other hand, when an amorphous thin strip group is thermally
processed after formation of eyelet structure 3a, it is preferable
to make a thermal gradient in a lamination direction small and make
a heat processing temperature distribution in the lamination
direction uniform. Furthermore, the quantity of heat of
self-heating when the thin strips are crystallized from the
amorphous state accumulates at a lamination center portion, and a
temperature excessively rises. On the other hand, the quantity of
heat of self-heating of the thin strips is correlated with the
thickness. In view of this, the thickness of magnetic-plate
laminate 1 is preferably the thickness equal to or less than 2.5 mm
to suppress the excessive temperature rise. This shows that desired
magnetic characteristics can be obtained. In this case, some of
laminates 1 can be laminated to form one thick magnetic-plate
laminate 1.
When the entire thickness of magnetic-plate laminate 1 is 2.5 mm,
and the plate thickness of one sheet of a thin strip is minimum 10
.mu.m, 250 sheets of thin strips need to be laminated at maximum.
Furthermore, a plurality of sheets of thin strips is laminated and
manufactured to enhance productivity. The entire thickness in a
case of two sheets of the laminated thin strips is 0.02 mm since
the plate thickness of the thin strip is 10 .mu.m.
When the above material is used as the material of fastening member
100a, even if the thin strips are thermally processed and
crystallized, eyelet structure 3a does not melt.
This eyelet structure 3a makes it easy to transfer heat in the
lamination direction of magnetic-plate laminate 1 and contributes
to making the temperature gradient in the lamination direction
small.
Furthermore, it is desirable to leave a trace of a heat effect such
as an oxide on a surface of eyelet structure 3a. A layer of the
oxide has an insulation property, and consequently contributes to
preventing electrical short-circuiting between laminated
magnetic-plate laminate 1 and eyelet structure 3a, and can reduce
energy loss due to eddy current loss caused by short-circuiting in
a magnetic device such as a motor.
Embodiment 2
FIG. 3 is an external outlook view of fastening member 100b
according to Embodiment 2. A difference of FIG. 3 from fastening
member 100a in FIG. 1A is that planar portion 2b is vertically bent
on one side from hollow cylinder 2 from the beginning Planar
portions 2a are disposed in parallel to hollow cylinder 2 on the
other side. Thus, there is an advantage that it is easy to position
the fastening member in a thickness direction of magnetic-plate
laminate 1. A formation process of eyelet structure 3a and a shape
after formation of eyelet structure 3a are equivalent to those in
FIGS. 1D and 2. Matters which are not described are the same as
those in Embodiment 1.
Embodiment 3
FIGS. 4A to 4C are schematic views illustrating a manufacturing
process of magnetic-plate laminate 1 of a magnetic plate according
to Embodiment 3. More specifically, FIGS. 4A to 4C illustrate that
fastening member 100c is used for a metal fastening mechanism, and
caulking structure 3b is formed.
In this regard, a through-hole is not made in caulking structure 3b
unlike eyelet structure 3a, and therefore planar portions 10a are
located at both ends of solid columnar body 10 in this structure.
One end widens as planar portions 10a to intend to collectively fix
the laminated thin strips. Instead of a plurality of planar
portions 10a, one planar portion 10a is formed unlike planar
portions 2a and 2b. In this regard, planar portion 10a may be
divided into several portions. Matters which are not described are
the same as those in Embodiment 1.
A difference of FIGS. 4A to 4C from FIGS. 1B to 1D is that
fastening member 100c is used. In FIG. 4A, fastening member 100c is
inserted in opening 4 of laminated magnetic-plate laminate 1 in an
arrow direction.
In FIG. 4B, fastening member 100c is fixed by pressing mechanisms
5, and compressing fittings 7 are butted from upper and lower sides
in arrow directions.
Furthermore, in FIG. 4C, compressing fittings 7 can compress
columnar body 10 in the arrow directions to form planar portions
10a on the upper and lower sides of columnar body 10 in a vertical
direction and form caulking structure 3b.
FIG. 5 is a cross-sectional view illustrating a state where
laminated magnetic-plate laminate 1 is fixed by caulking structure
3b. A material of fastening member 100c which forms caulking
structure 3b is desirably a non-magnetic material which is not
influenced by a magnetic field from a viewpoint that this material
does not influence magnetic characteristics of magnetic-plate
laminate 1 similar to eyelet structure 3a. This is similar to
Embodiment 1, and, for the material of fastening member 100c which
forms caulking structure 3b, an iron-based material such as
austenitic stainless steel, or a non-ferrous metal such as a
cooper, a copper-based alloy such as brass, aluminum or an aluminum
alloy, or an alloy of these can be used.
Embodiment 4
FIGS. 6A and 6B are schematic views illustrating a process of
forming eyelet structures 3c of magnetic-plate laminate 1 of a
magnetic plate according to Embodiment 4. In FIG. 6A, opening 55 is
made by drill 12 at an axial center of one of two caulking
structures 3b formed in laminated magnetic-plate laminate 1. In
FIG. 6B, when openings 55 are made at two portions, eyelet
structures 3c are formed. In this case, a cutting mark
(irregularity 24) is left in the inner wall of the opening of
eyelet structure 3c. Irregularity 24 is preferably 10 nm or
more.
Thus, matters which can be changed from caulking structure 3b to
eyelet structure 3c in the same process and are not described are
the same as those in the above embodiments.
(Embodiment 5) Caulking Manufacturing Method
FIGS. 7A to 7C are schematic views illustrating a manufacturing
process of magnetic-plate laminate 1 according to Embodiment 5, and
illustrate magnetic-plate laminate 1 for which caulking structure
3d is used. A difference of FIGS. 7A to 7C from FIGS. 4A to 4C is
that a columnar fastening member 100d is used.
In FIG. 7A, fastening member 100d which is longer than the depth of
opening 4 and is larger than the volume of opening 4 is inserted in
opening 4 of laminated magnetic-plate laminate 1 in an arrow
direction.
In FIG. 7B, laminated magnetic-plate laminate 1 is fixed by
pressing mechanisms 5, and caulking fittings 16 having counterbored
portions 15 are butted from upper and lower sides in arrow
directions.
Furthermore, in FIG. 7C, caulking fittings 16 compress fastening
member 100d in the arrow directions, so that part of fastening
member 100d plastically flow and is loaded to counterbored portions
15 to form guards on the upper and lower sides and fix laminated
magnetic-plate laminate 1 by caulking structure 3d. Furthermore,
the shape of fastening member 100d may be a prismatic shape or a
spherical shape other than the columnar shape. Matters which are
not described are the same as those in the above embodiments.
Embodiment 6
FIG. 8 is an enlarged cross-sectional view near caulking structure
3d of magnetic-plate laminate 1 according to Embodiment 6. A
non-ferrous material has lower hardness than an iron-based material
as a material of caulking structure 3d, and can be caulked with a
small load.
Particularly when a low melting point alloy such as a solder is
used as caulking structure 3d, a yield stress is low and a melting
point is also low. A heat processing temperature of 350.degree. C.
to 500.degree. C. exceeds the melting points of multiple solders,
and therefore part of caulking structure 3d flows in gaps 20 of
thin strips 19, and leaves projection portions 21 of projection
shapes. When these projection portions 21 enter between the layers
of thin strips 19, there are also advantages that there is little
gap in a lamination direction, and a fixing state is more firm.
Matters which are not described are the same as those in the above
embodiments. Projection portions 21 are located on a side surface
of the columnar portion of caulking structure 3d. A plurality of
projection portions 21 is preferably provided.
An eyelet structure also needs to include these projection portions
21.
Embodiment 7
FIG. 9 is an enlarged cross-sectional view near fastening member
100d of a magnetic-plate laminate according to Embodiment 7. A
difference of fastening member 100d in FIG. 9 from caulking
structure 3b in FIG. 5 is that an outer peripheral portion of
fastening member 100d is provided with insulation layer 23. In FIG.
7A, by providing insulation layer 23 such as a resin which can
deform on an outer peripheral portion of caulking member 14, and
performing caulking in the same process as those in FIGS. 7B and
7C, a structure in FIG. 9 can be obtained. By providing insulation
layer 23 on outer peripheral of fastening member 100d, it is
possible to prevent electrical short-circuiting between laminated
magnetic-plate laminate 1 and fastening member 100d, and reduce
energy loss due to eddy current loss caused by short-circuiting in
a magnetic device such as a motor. Matters which are not described
are the same as those in the above embodiments.
In addition, preferably, above fastening members 100a to 100c also
include insulation layers 23 on outer peripheral surfaces or inner
peripheral surfaces of fastening members 100a to 100c likewise.
Embodiment 8
FIGS. 10A and 10B are external outlook configuration diagrams of a
motor formed by magnetic-plate laminate 1 of a magnetic plate
according to Embodiment 8. FIG. 10A is a side view of the motor,
and FIG. 10B is a top view of the motor.
In FIG. 10A, stator 31 which is a laminated object of thin strips
is fixed to fixing plate 32 by bolts 33, spring washers 34, washers
35 and nuts 36. In FIG. 10B, windings 38 are provided to portions
which are called teeth (T-shaped protrusion portions) of stator 31.
Rotor 37 is installed on an inner diameter side (opening portion)
of stator 31.
FIGS. 11A and 11B are cross-sectional configuration diagrams
between A and A' in FIG. 10B, FIG. 11A illustrates a state without
fixing bolts 33 and FIG. 11B illustrates a state with bolts 33.
In FIG. 11A, laminates 41 of eyelet structures 3a and 3c which form
stator 31 are positioned such that portions of eyelet structures 3a
and 3c are stacked on through-hole 42 for fastening fixing plate
32, and are laminated at three stages. Metal fastening mechanisms
(openings 4 and fastening members 100a and 100b) are linearly
arranged in a thickness direction of stator 31.
In FIG. 11B, laminates 41 of eyelet structures 3a and 3c are fixed
to fixing plate 32 by bolts 33, spring washers 34, washers 35 and
nuts 36. By inserting bolts 33 in eyelet structures 3a and 3c in
openings 4 of laminates 41, it is possible to prevent damages on
end surfaces of the thin strips during insertion of the bolts 33.
Furthermore, by stacking and laminating eyelet structures 3a and
3c, fastening pressures of the bolts 33 locally work on the thin
strips, so that it is possible to prevent a negative influence on
magnetic characteristics of laminates 41.
Laminates 41 are used for stator 31. However, laminates 41 may be
used for rotor 37. A motor whose rotor 37 rotates around stator 31
may be used.
Embodiment 9
FIG. 12 is an enlarged cross-sectional configuration diagram near
eyelet structure 3c of stator 31 of a motor according to Embodiment
9. Laminates 41 of eyelet structures 3c including fastening members
100e with insulation layers 23 are laminated at three stages.
Furthermore, adhesive 43 is applied to an inner wall of opening 4
inside fastening member 100e to couple laminates 41 of three
stages. By adhering laminates 41 of eyelet structures 3c, it is
possible to handle stator 31 alone even if bolts are not used for
fastening, so that handling becomes easier.
Adhesive 43 is used for coupling in FIG. 12. However, fastening
members 100e may be welded to each other or fastening members 100e
may be caulked to each other. Matters which are not described are
the same as those in Embodiment 8.
Embodiment 10
FIGS. 13A and 13B are external outlook configuration diagrams of a
motor formed by a magnetic-plate laminate according to Embodiment
10, FIG. 13A is a side view and FIG. 13B is a top view. The motor
in FIGS. 13A and 13B is different from a motor in FIGS. 10A and 10B
according to Embodiment 8. Difference points include that (1)
stator 31 which is a laminated object of thin strips is fixed at
three portions of fixing plate 32 by bolts 33, spring washers 34,
washers 35 and nuts 36, and (2) resin portions 44 loaded in
openings 4 of the fastening members are provided at three portions.
That T-shaped portions which are called teeth of stator 31 are
wound by windings 38 and rotor 37 is installed on an inner diameter
side of stator 31 is the same as that in FIGS. 10A and 10B.
FIG. 14 is a cross-sectional configuration diagram between B and B'
in above FIG. 13B, and illustrates a state where laminates 45 of
eyelet structures 100a, 100b and 100e are laminated before fixing
bolts 33 and resin portions 44 are inserted. Laminates 45 of the
eyelet structures which form stator 31 are laminated at five stages
such that through-holes 46 and hollow portions 47 of fastening
members 100e are alternately stacked. That is, fastening members
100e adjacent on the upper and lower sides are located at different
positions in a plan view of stator 31. Alternatively, fastening
members 100e adjacent on the upper and lower sides are not
combined.
This configuration provides an effect that upper and lower gaps 48
of laminated magnetic-plate laminate 1 narrow and a space factor is
high compared to a case where eyelet structures 3a and 3c are
stacked and laminated at three states in FIG. 11A in Embodiment
8.
FIG. 15 is a cross-sectional configuration diagram between B and B'
in above FIG. 13B, and illustrates a state where laminates 45 of
the eyelet structures are laminated and fixed after fixing bolts 33
and resin portions 44 are inserted. Laminates 45 of the eyelet
structures are fixed to fixing plate 32 by bolts 33, spring washers
34, washers 35 and nuts 36 via through-holes 46 and hollow portions
47 of fastening members 100e. Furthermore, resin portions 44 loaded
to keep rigidity are formed in laminates 45 in which bolts 33 are
not inserted. Even when resin portions 44 are hollow, other
materials may be loaded. Matters which are not described are the
same as those in Embodiments 8 and 9.
CONCLUSION
The embodiments can be combined. The eyelet members and the
caulking members may be columns, columnar cylinders, square columns
or elliptical columns.
In addition, the present disclosure includes any combination of
optional embodiments and/or examples among the above-described
various embodiments and/or examples, and can provide the effects of
the respective embodiments and/or examples.
INDUSTRIAL APPLICABILITY
The magnetic-plate laminate according to the present invention can
provide the magnetic-plate laminate which has high productivity
without impairing magnetic characteristics. Consequently, the
magnetic-plate laminate according to the present invention is
useful as the stator of the motor. Furthermore, the magnetic-plate
laminate according to the present invention is applicable for use
in magnetic application electronic parts such as transformers other
than motors.
REFERENCE SIGNS LIST
1 Magnetic-plate laminate 2 Hollow cylinder 2a, 2b Planar portion
3a, 3c Eyelet structure 3b, 3d, 3e Caulking structure 4 Opening 5
Pressing mechanism 6 Eyelet fitting 7 Compressing fitting 10
Columnar body 10a Planar portion 12 Drill 15 Counterbored portion
16 Caulking fitting 19 Thin strip 20 Gap 21 Projection portion 23
Insulation layer 24 Irregularity 31 Stator 32 Fixing plate 33 Bolt
34 Spring washer 35 Washer 36 Nut 37 Rotor 38 Winding 41 Laminate
42 Through-hole 43 Adhesive 44 Resin portion 45 Laminate 46
Through-hole 47 Hollow portion 48 Gap 51 Lamination member 52
Amorphous alloy thin strip 53 Electromagnetic steel plate 55
Opening 100a, 100b, 100c, 100d, 100e Fastening member
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